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MIG Welding gauge steels and alloy steel parts < 1/8 (< 4
mm).
The bove actually happened because the plant management and
engineersresponsible for the bomb lug welds did not understand or
take ownership ofthe MIG weld process and equipment used in their
plant.
HAVE YOU SEEN THE WORLD'S BEST WELD PROCESS TIP TIG?
www.tiptigusa.com.
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THIS UNIQUE WELD PROCESS PROVIDES LESS WELD HEAT AND BETTER
WELDQUALITY THAN ANY TIG OR MIG WELD AND PROVIDES THO WELDS AT A
THIRD OFNORMAL TIG WELD COSTS.
Welcome to MIG Short Circuit welding and Pulsed MIG onCARBON
STEELS AND STAINLESS GAGE APPLICATIONS.
As the pulsed MIG process painfully evolved over the last few
decades, the utilization ofshort circuit decreased for gauge,
carbon steel applications. The weld reality is that incontrast to
pulsed MIG, the lower cost traditional CV MIG equipment that
provides shortcircuit welding can offer many unique superior weld
attributes for most thin gaugesteels and alloy steels none code
weld applications.
Note: This site has been a weld blog long before the word blog
was discovered. Thissite cuts out the salesmanship from an industry
that depends on sales advice anindustry that has too many weld
decision makers that have to play around with 50 yearold simple
weld controls.
This site brings the weld process contol expertise I gained over
40 years and this sitebrings the opinions of other weld personnel
that also strive to see this industry gain therespect it
deserves.
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During short circuit weldtransfer, unlike the open arcpulsed,
globular or spraytransfer modes, the uniqueshort circuit arc spends
50% ofit's time in the "arc off"
condition.
When the electrode positiveshort circuit weld wire makescontact
with the negativegrounded part it's in the arc offcondition. This
cold conditionis controlled by the powersource slope. With the
shortcircuit, the resistance to thecurrent is lowered, the
weldvoltage drops and the current
rises to the slopes limit. The short circuit current rise is
sufficient to melt the wire tip
and form an arc which results in the formation of a fluid
droplet that quickly develops onthe MIG wire tip.
As the short circuit wire feed is constant, the weld
dropletbeing formed is driven to the weld and also drawn
bycapillary action into the surface of the weld. The shortcircuit
weld droplet is detached and the wire is driven tothe weld to
repeat the arc off, arc on cycle which typicallyoccurs 60 to 120
times per-second.
Note: With argon gas mixes, the argon mix gas plasma
(asindicated in the video below) partially covers the fluid
droplet during it's formation. In contrast, when usingstraight
CO2, the CO2 plasma would be at the bottom of the weld droplet,
supporting thedrop and disturbing the drop till it gets larger and
then transfers in an erratic manner.
A UNIQUE ATTRIBUTE OF SHORT CIRCUIT TRANSFER WELDING: The short
circuitmode is the only weld metal transfer in which the arc goes
on - off. The "arc on - off"weld attribute is a logical weld
benefit on thin gauge, or applications which require agap has to be
bridged.
If welding stainless and steel thin gauge applications, short
circuit is an excellent weldtransfer mode, however stainless
produces more sluggish welds than carbon steelwelds. The sluggish
welds welds are especially noted on stainless parts > 0.080. If
youwant gage welds with minimum distortion, minimum spatter and
minimum cleaning,watch what TIP TIG www.tiptigusa.com can do for
thin stainless in the following video.
REGULAR TIG VERSUSTIP TIG ON THIN GAGE APPLICATIONS:
http://www.weldreality.com/TIP-TIG-Welding.htmhttp://www.weldreality.com/TIP-TIG-Welding.htmhttp://www.weldreality.com/TIP-TIG-Welding.htm
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REGULAR TIG: YOU CAN USE REGULARTIG, TAKE TOO MUCH TIME, PUT IN
TOOMUCH WELD HEAT AND MAKE WELDSLIKE THIS. PLAY THIS VIDEO
FIRST
TIP TIG: YOU COULD GET ON WITH YOUR LIFE,REDUCE YOUR WELD COSTS.
MAKE HIGHQUALITY TIP TIG WELDS LIKE THIS WITH MUCHLESS HEAT
INPUT.
REGULAR TIG: Play this video first:Regular TIG typical manual
weld speeds forthese welds is 4 to 7 inch/min.
The TIG arc on time for this 12 inch weldwould be around 2- 3
minutes. Take a look
at the irregular weld quality influenced bytoo many arc start /
stops, and take specialnote of the large heat affected zone
that'sgoing to create distortion concerns.
Someone can always do a better TIG weldthan this but it will
never match the qualityand productivity attained with TIP TIG.
TIP TIG: Manual TIP TIG weld travel rate48 inch/ min as noted on
the UTube secondcounter with this 12 inch length of 3 mm weldmade
with an arc on time of 15 seconds:
Note the uniform weld quality that comes from theconstant wire
feed rate and only one arc start /stop. Examine the smooth clean,
unoxidized weldsurface, the very small HAZ and lack of
welddistortion and weld minimal fumes. Think aboutthe savings that
will results from less cleaning.
From welding small, long track, 3 mm fillet weldson the deck of
an Aircraft Carrier to the small sizestainless welds typically
found on food andbeverage / processing equipment, no other
weldprocess can provide long, small size gage weldswith the TIP TIG
quality and the lowest possibleweld heat input.
On robot stainless gauge applications > 0.070, thanks to the
increased weld speedpotential, low spray parameters and an 0.035
wire can be used. Pulsed MIG with 0.045wire is also applicable but
not necessary when manual welding > 16 gauge stainless
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parts.
A Short Circuit and Pulsed Transfer WeldConsideration.Short
circuit welding transfer available from a lowcost, constant
voltage, (CV) traditional MIG power
source with an 0.035 (1mm) wire is suited for allmanual steel
applications from 20 to 12 gauge.
Note: A benefit of the pulsed mode for some > 16 gauge
applications is the lower cost,easier to feed, 0.045 (1.2 mm)
carbon steel or stainless wire may be used instead of the0.035 (1
mm) wire. 045 wire provides a little more deposition which may be
beneficialwhen larger welds are required on specific thin parts. As
a lower cost weld equipmentalternative you could take regular, much
lower cost CV MIG equipment and set that0.045 in the globular mode
and achive the same deposition as the pulsed MIG..
Designers and manufacturing engineers and managers of gage
applications often sufferfrom a lack of MIG weld process knowledge
and that can lead to dramatic weld costconsequences.
When welding thin, carbon steel or stainless robot welded parts
< 2mm you may find;
[a] unacceptable part part tolerances,[b] unacceptable weld
gaps,
[c] poor part fixtures,[d] inappropriate weld joint designs,[e]
poor consumable wire size selection and weld equipment with poor
performance,[f] poor weld parameters and poor technique.
Of course items A to F will lead to weld rework and weld cost
ramification. Commonissues are weld burn through, distortion,
spatter leading tp weld rejects and extensiveor rework. To add to
the thin gauge weld issues, it's a sad fact that the majority
manyautomotive and truck manufacturing plants that use MIG welding
robots, lack the
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engineering ability to select the correct size MIG wire or the
optimum weld transfermode for the application.
ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES. A FEW OF HIS
PROJECTS,FORD F 150 FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES-
HARLEY BIKE FRAMES -NEW BEETLE CAR SEATS AND THE ROBOT WELDS ON THE
WORLD'S LARGESTCATERPILLARTRUCK.
Ed's unique manual and robotMIG Process Control Training
Programs
STEEL GUAGE CHART, OPTIMU WIRE SIZE & WELDING GAS
MIXTURE.
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Gauge to inch conversion
GAUGE 3 = 0.239 inch O.6 cmGAUGE 4 = 0.224 inch 0.56 cm
CONSIDER 0.045 (1.2 mm) WIRE. ARGON-10-15 C02 FOR THESE MANUAL /
ROBOT SPRAY
/ PULSED WELDS.
GAUGE 5 = 0.209 inch 0.53 cmGAUGE 6 = 0.194 inch 0.49 cm
CONSIDER 0.035 (1 mm) WIRE.ARGON-10-15% C02 FOR MANUAL /
ROBOTSPRAY. IF USING PULSED USEDAN 0.045 WIRE WITH THE SAME GAS
MIXES.
GAUGE 7 = 0.179 inch 0.45 cmGAUGE 8 = 0.164 inch 0.41 cm
CONSIDER 0.035 (1 mm) WIRE. ARGON 5-10%
C02 OR ARGON 2 TO 5% OXYGEN FOR THISMANUAL / ROBOT SPRAY WELD .
IF USINGPULSED USED AN 0.045 WIRE WITH THESAME GAS MIXES
GAUGE 9 = 0.15 inch 0.37 cmGAUGE 10 = 0.135 inch 0.34 cm
CONSIDER 0.035 1 mm WIRE.
ARGON 5-10% C02 OR 2 TO 5% OXYGEN FORTHIS MANUAL / ROBOT SPRAY
WELD. IFUSING PULSED USED AN 0.045 WIRE WITHTHE SAME GAS MIXES,
GAUGE 11 = 0.12 inch 0.3 cmGAUGE 12 = 0.105 inch 0.26 cm
CONSIDER 0.035 1 mm WIRE ARGON 15-20%C02 FOR THIS MANUAL SHORT
CIRCUITGAUGE. THIS CAN ALSO BE SPRAY ORPULSED SPRAY WELDED WITH A
ROBOTUSING THE 035 WIRE AND 5 -10% CO2 OR 2-5OXYGEN. IF USING
PULSED USE AN 045WIRE WITH 5 TO 10 CO2.
GAUGE 13 = 0.09 inch 0.22 cmGAUGE 14 = 0.075 inch 0.19 cm
CONSIDER 0.035 1 mm WIRE.ARGON 15-20% C02 FOR THIS MANUAL
SHORT CIRCUIT GAUGE. THIS CAN ALSO BESPRAY WELDED WITH A ROBOT
USING 5 -10% CO2 OR 2-5 OXYGEN. IF USING PULSEDUSED AND 0.045 WIRE
WITH THE SAME GASMIXES
GAUGE 15 = 0.067 inch 0.17 cmGAUGE 16 = 0.06 inch 0.15 cm
CONSIDER O.035 (1 mm) WIRE ARGON 5- 10%C02 FOR THIS SHORT
CIRCUIT GAUGE. IFUSING PULSED USE AN 045 WIRE AND 10
CO2.
GAUGE 17 = 0.054 inch 0.13 cmGAUGE 18 = 0.048 inch 0.12 cm
CONSIDER 0.035 1 mm WIRE.ARGON 5-10% C02 FOR THIS SHORT
CIRCUITGAUGE. IF USING PULSED USE AN 0.045
WIRE WITH THE SAME GAS MIXES
GAUGE 19 = 0.042 inch 0.11 cm
GAUGE 20 = 0.035 inch 0.08 cm
CONSIDER 0.035 1 mm WIRE ARGON 5 TO 10CO2 / ARGON 2% Oxy FOR
THIS SHORTCIRCUIT GAUGE. USING PULSED USE AN 045
GAUGE 21 = 0.033 inch 0.08 cm
GAUGE 22 = 0.03 inch 0.07 cm
CONSIDER 0.030 0.8 mm WIRE ARGON 5%OXYGEN FOR THIS SHORT
CIRCUIT. USINGPULSED? USE AN 035 WIRE WITH THE SAMEARGON OXY MIX
GAUGE
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WIRE AND LOW ENERGY ARGON 5 TO 10CO2.GAUGE 23 = 0.027 inch 0.06
cmGAUGE 24 = 0.024 inch 0.06 cm
CONSIDER 0.030 (0.8 mm) WIRE ARGON 5%OXYGEN FOR THIS SHORT
CIRCUIT GAUGE,BE CONCERNED ABOUT WIRE FEED ISSUESWITH 030. USING
PULSED? USE AN 0.035WIRE WITH THE SAME ARGON OXY MIX...
WELDING STAINLESS STEEL ? USE THESAME RECOMMENDATIONS WITH ARGON
2-5% CO2. ALSO CONSIDERTIP TIG
E-mail. Weld Question, 06 /20/03
Hi Ed, I would like to know what the critical factors are that
determineshorty circuit weld fusion. I often wonder if short
circuit transfer simplywon't put heat into the base metal fast
enough to achieve fusion onanything greater than gauge thickness.
Right now I have a single phase,Miller 185 amp power source. We
weld steel and silicon bronze base metalfor architectural work,
balconies, railings, etc. Typically we are joining 1/2to 3/4 inch
square tubes to 1/2 x 1 to 1/2 x 2 with single and double bevel
prep. I find I must run in globular mode with the 0.035 wire we
use. I don't think the
Miller 185 will get me into spray transfer and am trying to
decide if a machine in the 250amp class is the solution. We are
currently stuck with single phase power What is yourtake on all
this?
Regards, Erik Lander.
The scourge of the weld industry.
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If every MIG weld in North America was sectionedtomorrow, the
majority would reveal lack of fusion.
Ed's reply. Erik, with manual short circuit transfer, depending
on the steel
application you should be concerned about fillet weld fusion
oncomponents over 0.100 and consider pulsed, controlled globular or
lowspray settings for these applications.
Using argon 10 to 20% CO2, an 0.035 (1 mm) steel wire will
require >200amps to attain optimum spray transfer, that's why
the CV. "250 amp" power
source is a popular equipment choice for sheet metal shops. With
your low currentpower source, you could get a lower spray
transition current if you used argon oxygenoxy mix (try 2% oxy or
5%CO2). With argon oxy mixes you will get into spray around
180amps, however, note these argon oxy gas mixes are not suited for
short circuit transfer.If you really want to get into spray with
argon CO2 mixes on your power source, youwould have to use an 0.030
(0.8mm) MIG wire, however I would not recommend that asyou could
then expect wire feed issues with this small wire.
A logical solution with your power source when welding carbon
steel welds, giveconsiderations to an 0.035, E71T-1, gas shielded
flux cored wire with argon - 25 % CO2.With these consumables and
your small power source you could weld any metalthickness in any
position. Good luck Ed.
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ROBOT AND MANUAL MIG DATA DIFFER:
MIG welding data recommendations can change dramatically
whenchanging from manual to automated welds. In contrast to manual
welding,when welding thin gauge applications with robots, the welds
typically canbe made with "higher weld travel speeds" which allows
higher weld currentsettings or different weld transfer mode
options.
Pulsed spray transfer " allows robot welds to be made on carbon
steel oralloy steels in the thickness range of 0.045 (1.2 mm) to
any thickness.
Robot welds using 0.035 (1mm) wire with regular "spray transfer"
set at low weldingspray parameters can be used on parts as thin as
>0.070, >1.8mm. No weld gaps andshort weld lengths
preferred.
Robot welds with an 0.035 wire with short circiut can weld parts
> 1 mm, under 1 mm theweld burn through risks are high,
Globular Benefit: For welding those exhaust components or Harley
bike frames that arepoorly put together and end up with weld gaps,
an alternative weld transfer mode topulsed and short circuit is the
globular transfer mode. For globular weld transfer use0.035 wire
typically set at 400 to 600 ipm with a weld voltage range of 20 to
24 volts. Thismode provides low to medium weld energy at higher
weld deposition than short circuitand on round parts there will be
low weld spatter.
I BELIEVE EVERY MIG WELDING DECISION WILL BENEFITFROMTHESE 3
BOOKS.
[1] MY "MIG AND ROBOT WELD PROCESS CONTROL"BOOK.
[2] MY "MANAGEMENT AND ENGINEERS GUIDE TO MIG"BOOK.
[3] MY "MANUAL MIG & FLUX CORED BOOK".
Note: These books and my MIG self teaching / training video and
MIG process controlCD's are found in the training resources section
of this site(click here).
My process control training resources, simplify the selection of
optimum MIG wire feedand volt settings for all common electrode
diameters used on manual and robotapplications. The process
controlwelding CD'swill provide your robot personnel andwelders
with the ability to instantly set the optimum MIG weld transfer
modes and weldparameters for any steel application.
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Two important steps for effective weld process controls.
[1] Avoid weld sales advice.
[2] Take a logical process approach in selecting the optimum MIG
wirediameter for your applications.
Lets see. If we have traditional CV MIG equipment, the 0.035 or
0.040(1 - 1.1mm) MIG wire diameters provide a short circuit weld
current range that is bestsuited for the common thin 20 - 12 gauge,
steel and stainless applications. We shouldavoid using smaller MIG
wires as they are not necessary and they can create wire feed
issues.
OVERSIZE MIG WIRES AND POOR CONSUMABLE CHOICES:
For decades many auto / truck managers believed that when it
comes towelding"the cheaper bigger MIG weld wires are better and
will povide costreductions"
[] The use of oversize MIG wires 0.045 - 0.052 - 0.062 which
require too high weld currentfor gage parts is common in the
majority of plants.
[] The use of self shielded flux cored wires is also common.
Take note; These weld wireshave no place in any plant in which
desires consistent optimum weld quality.
[] While the majority of plants that use argon mixes utilize the
E70S-6 wires. The weldreality is that the E70S-3 wires would have
less oxides islands on the surface, lessporosity and less undercut
potential. Reducing oxides is important when welds are tobe painted
or coated.
To attain optimum weld transfer from the over sized diameter MIG
wires requires highweld current and typically the current required
will not be compatible with the gaugesize welded. The bottom line
is the auto industry needs managers who understand theimportance of
weld consumable selection, weld process controls and best
weldpractices.
My process control trainingprogramssimplify and teach the best
practices - processcontrol requirements and anyone who can read
English can present these programs.
SELF SHIELDED FLUX CORED WIRES ARE THE WORLD'S WORST WELD WIRES
YETTHEYARE A COMMON CONSUMABLE CHOICE FOR MANY IN THE AUTO / TRUCK
INDUSTRY.
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SELF SHIELDED FLUX CORED WIRES AND WELD PROCESS IGNORANCEBY
CHRYSLER, CAUSED MILLIONS IN UNNECESSARY WELD COSTS:
2006: WHEN I SEE SELF SHIELDED FLUX CORED WIRES USED IN ROBOT
CELLS OR INANY INDOOR WELD APPLICATION, APART FROM WANTING TO THROW
UP AND HOLDMY NOSE TO AVOID THE AFFECTS OF THOSE OBNOXIOUS WELD
FUMES, I KNOWTHE PLANT SUFFERS FROM THAT INFAMEOUS GLOBAL WELD
DISEASE CALLED"managementprocess - ignoranceitis.
AT THE TIME I WROTE THIS BOTH CHRYSLER AND GM MANAGEMENT
AREREQUESTING USE OF THESE WELD WIRES FOR THEIR GALVANEALED PARTS
WHICHIS IRONIC AS THESE WIRES OFFER NO BENEFITS FOR GALVANEALED
ORGALVANIZED. THANKS TO THE WELD ISSUES THE USELESS SELF SHIELDED
WIRESGENERATE, THESE FLUX CORED CONSUMABLES EACH YEAR WILL
COSTCORPORATIONS MILLIONS OF DOLLARS IN LOSS OF ROBOT OR MANUAL
WELDPRODUCTIVITY, WELD PART REJECTS, EMPLOYEE TURN OVER FROM
THE
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OBNOXIUS WELD FUME ISSUES IN WHICH MORE WORKERS SHOULD BE
TAKINGLEGAL ACTIONS AND ALWAYS EXTENSIVE WELD CLEANUP AND
WELDREWORK.
MANY PLANTS WILL USE 0.045 (1.2mm) AND 0.052 (1.4mm) MIG WIRES
WITH THEIRCV, SHORT CIRCUIT OR GLOBULAR MODES TO ROBOT WELD PARTS
LESS THAN0.100.THESE LARGE WIRES ARE THE FREQUENT CAUSE OF WELD
BURN THROUGH,
DISTORTION AND WELD REWORK ISSUES.
MANY PLANTS, ESPECIALLY AUTO / TRUCK FRAME PLANTS WILL ROBOT
WELDPARTS 1 TO `4 mm AND USE AN 0.052 (1.4 mm) WIRE, YET THE SPRAY
CURRENTWITH THESE WIRES IS BETTER SUITED TO WELDING PARTS > 5
mm
AT THE INFAMOUS "QUALITY IS JOB 1" FORDFRAME PLANT IN DETROIT,
MIG WELDING THETRUCK FRAMES WAS MORE OF A COMEDY SKITTHAN AN
ENGINEERED, CONTROLLEDFUNCTION.
THE FORD PLANT AND IT'S ENGINEERS AND MANAGERSSIMPLY HAD NO
UNDERSTANDING OF THEREQUIREMENTS OF ROBOT WELD PROCESS CONTROLSAND
THE PLANT CONSTANTLY USED UNDER TRAINEDEMPLOYEES AND OVERSIZED MIG
WIRES ON IT'S ROBOTMIG WELDING TRUCK FRAME LINES.
THIS IS HOW FORD IMPLIMENTS "QUALITY IS JOB 1". ATONE OF IT'S
PLANTS. YOU WOULD FIND AN EMPLOYEE ATTHE END OF THE ROBOT LINE. HIS
JOB WAS TO USE ACHEAP SWEEPING BRUSH, DIP IT IN BUCKET CONTAINING
YELLOW PAINT AND TRY
TO MARK THE NUMEROUS BAD WELDS ON EACH FRAME AS THEY PASSED AT
THERATE OF ONE A MINUTE. THIS PLANT AND OTHER FORDFACILITIES HAS
FOR DECADES HAD THE PROUD ENGINEERINGACHIEVEMENT OF NEVER PRODUCING
A ROBOT WELDEDFRAME, WITHOUT MOST WELDS REQUIRING WELD REWORK.
OVERSIZE MIG WIRES WILL NOT ALLOW THE USE OF SPRAYTRANSFER WHICH
DID NOT MATTER FOR MANY COMPANIES THAT DID NOT KNOWWHAT SPRAY
TRANSFER WAS. OFTEN THE OVERSIZED WELD WIRES END UP BEINGUSED IN
THE GLOBULAR TRANSFER MODE. GLOBULAR WELD TRANSFER WAS VERYCOMMON
AT FORD, GM, DANA, TOWER AND CHRYSLER PLANTS. THE GLOBULARMIG WELDS
WILL TYPICALLY LACK WELD FUSION, CAUSE EXCESS SPATTER ANDCAUSE
CONTACT TIP ISSUES RESULTING IN EXCESS WELD REWORK AND ROBOTDOWN
TIME.
Weld Wire Facts: Welding carbon steels or stainless steels with
an0.035 or 0.045 (0.9 - 1.2 mm) MIG wire, short circuit transfer on
mostapplications is found in the weld current range of approx. 80
to 190
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amps.
Optimum short circuit transfer with 0.035 (0.9mm) wires is
typically found between 100and 180 amps with a voltage range 15 to
18 weld volts and provides optimum weldresults on parts <
0.100.
On the applications that utilize the 0.035 wires in the optimum
short circuit currentrange, pulsed MIG using an 0.045 wire can also
be used with similar or slightly higherweld current and deposition
rates.
In contrast to the "arc on - arc off", short circuit transfer
mode, thepulsed mode is an "open arc" mode that delivers the
dropletsacross the arc in a consistent transfer, that is if you
havepurchased one of the rare pulsed power sources that
actuallyworks in a consistent manner. In contrast to short circuit
transfer
set at 150 amps, the OPEN ARC pulsed process set at150 ampswill
deliver a weld with greater weld energy.
Note If you were producing manual or robot short circuit welds
at 180 amps and youwant to try an 0.045 and the pulsed process, I
would start the pulsed weld at 160 amps,then adjust.
Optimum Short Circuit Transfer and Pulsed MIG Wire Diameter
Selection for GaugeApplications.
CV Regular MIG Equipment. The best two MIG wire diameters for
shortcircuit transferare 0.035 and 0.040 (0.9 and 1.1 mm). In
industrial shops, there is
simply no justification for the use of smaller weld wires and if
thetypical thickness worked on does not exceed 7 mm there is no
justification for larger wires...
Pulsed MIG The best MIG wire diameter for all carbon steels,
stainlessand aluminum gauge applications is the 0.045 (1.2 mm)
wire.
THE UNIQUE "0.040" MIG WELD WIRE, THE WIRE THE AUTOMOTIVE
WELD INDUSTRY SHOULD HAVE BEEN USING FOR AT LEAST
THREEDECADES:
Using traditional MIG CV equipment: If you could get your hands
onthe 0.040 (1.1 mm) wire, it would be the most practical choice
for mostrobot and manual MIG short circuit and low current spray
carbon andstainless applications in the 1.2 to 7 mm range.
The 0.040 MIG wire would require less current than the 0.045
wire which is especiallybeneficial for the 3 - 7 mm parts and the
040 wire would provide higher deposition and
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better feedability than the 035 wire. The lack of use of this
wire should be no surprise ina play around weld industry that
rarely implements Best Weld Practices.
NOTE ON ATTAINING 0.040 MIG WIRES: In North America for more
than two decades,Lincoln Electric has been in a monopoly position
in the sales of MIG wires. Lincoln doesmake small quantities of the
0.040 carbon steel MIG wire, however as Lincoln typically
has had a hard time keeping up with the demand for it's
traditional 0.035 - 0.045 steelwire products they are not exited
about the sale of 0.040 wire. It's understandable thatfrom their
perspective, that without extensive customer demand and without
weldprocess educated consumers, there is little incentive for them
to market the 0.040wires.
[] The 0.040 wire, optimum short circuit current range is
approx. 130 - 190 amps. Thiscurrent range is well suited to short
circuit welds on the very common and 14 - 18 gaugecarbon steel and
stainless applications. In contrast to the 0.035 wires, with short
circuitwelds and the 0.040 wires, you can expect slightly higher
weld deposition rates andimproved wire feedability which is very
beneficial on robot gauge applications. The0.040 wire needs less
current to get into spray than the 0.045 wire making it the
weld
wire of choice for 3 to 6 mm spray transfer applications (less
undercut and distortionpotential).
[] If you cannot use 0.040 wire, the optimum weld wire for thin
gauge current is the 0.035wire which typically uses a working weld
current of approx. 100 to 180 amps.
[] The "optimum" short circuit weld current for the 0.045 wire
is approx. 170 - 200 amps.In contrast to the 0.035 or 0.040 wires,
the 0.045 (1.2 mm) wire operates in a narrow,short circuit wire
feed range that delivers higher weld current, thus being less
suited tothin gauge parts (
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While we blame China for bad manufacturing pratices, read
aboutthis USA Mid West exhaust manufacturer which for years
allowedit's welding department to use the wrong welding
polarity.
Question: Ed can you describe the difference between straight
and reverse polarity inMIG welding?.
Answer: As we can all likely do with some humor in our lives, I
thought, rather thananswer this common weld question in the
traditional manner, that I would tell you abouta real world welding
application I was involved in a few years ago.
A Midwest company that builds exhaust systems for the
aftermarket had major MIG weld quality problems. The absent ownerof
the company asked if I would visit his plant and report on
theplant's welding issues. He told me that some of his
customerswere complaining that the carbon steel welded flanges
werefalling of the exhausts during delivery to the auto
partssuppliers.
I arrived at the exhaust manufacturing plant just before
lunch.Like many automotive companies, the plant was too cheap
tp
pay $8 an hour for a receptionist. I waited 30 minutes in
thelobby and no one answered the phone. To get access to theplant,
I walked around to the back door. I entered the plant inthe middle
of the busy weld shop and my weld senses went
immediately on high alert. The "MIG weld sounds" I heard from
the approx. 40 MIG weldbooths were unique, but I had heard that
sound before. I heard a grunt from behind,then again it could have
been a pathetic sounding fart. As I slowly turned around I sawwhat
could only be called a Englisman's nightmare. Rednecks are not
restricted to thesouth and I was within spitting distance of the
meanest looking one i had ever seen.
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Thankfully he just grunted and did not ask me to squeal like a
pig. What I saw next wasevery weld managers nightmare. Follow this
link for the rest of thiswelding story
The bottom line on New Weld Products and"Supply and Demand".
Mostglobalweldshopsbecomeentrenchedwithunhea
lthyculturesandwiththeweldconsu
mables they use daily.
If a new weld product comes alongthat indicates it can provide
"real weld weld cost benefits" forthe users, then it's logical that
the end users should demand
that product. The fact thatweld shops rarely demand the best and
most cost effectiveweld equipment and consumables ia an indication
of the levelof the global weld process control and weld cost
expertisethat prevails in too many weld shops.
The companies who are typically reluctant to make a majorweld
transfer mode or weld consumable changes have oftenused incorrect
consumables for years. Eventually these lackof weld management
ownership, "play around" with the weldcontrol companies will move
the poorly suited consumables
and poor weld practices into their MIG robot cells.
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A frequent weld management solution to robot weld problems.
When they have robot weld quality issues they employ more
manual welders. When they have robot weld productivity
issues,
they order more robots.
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Weld Fact: When the unqualifiedmanager or engineers ask
theunqualified welders who have skills butminimal weld process
expertise, to tryout that new weld wire or gas or powersource, is
it any surprise when the
welders don't like the new products?
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modes.
If you use "three part gas mixes" for any carbon steels or
anystainless applications, you are not using weld process logic,
andtypically you have been getting weld advice from either
aninexpericed weld salesman or what we called in England a
shyster.
Let's see, we have another important step for weldprocess
control. When it comes to MIG gasselection we don't need to try a
different MIG gassix times a year. We don't need the advice of a
gassalesman and we should get rid of those costly,useless three
part gas mixes. The bottom line is allour steel and stainless MIG
welds can be made with a couple ofsimple argon CO2 gas mixes found
in the MIG gassectionat this
site. With all the money I am saving, I will be able to afford
thatdivorce lawer.
IF PULSED MIG EQUIPMENT WAS NOT AVAILABLE TO GLOBAL WELD SHOPS,
ITWOULDHAVE NO IMPACT ON THE INDUSTRIES THAT WELD CARBON STEELS
AND
STAINLESS.
WELD QUALITY & PRODUCTIVITY SHOULD NEVER BE AN ISSUE WITH
LOW COST, CVMIG EQUIPMENT:
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The weld process mode you select will depend on the weld
equipment and consumablesin the shop. With low cost CV MIG
equipment, the short circuit, spray or controlledglobular selected
can produce, low spatter or spatter free, optimum welds on most
steelapplications, that is if the welders have the ability to set
optimum MIG weld parameterswithout playing around with the weld
parameters.
With a traditional US. MIG power source in $2500 to $3500 range
and pulsed MIGequipment in the $6000 to $12,000 range, the wise
weld decision maker would placetheir focus on ensuring their weld
personnel receive process controltraining,that willenable them to
have the ability to fully utilize and optimize the performance of
the muchlower cost CV equipment.
"PLAYING AROUND" DOES NOT BELONG WITH BEST WELD PRACTICES
ORPROCESS CONTROLS.
2006:For five decades, emphasis in thewelding industry has been
on welding skillsrather than on weld process expertise. This isa
prime reason why most manual welders still"play around" with their
MIG weld controls andthe robots fill up their weld rework
baskets.
IN AN INDUSTRY THAT PLACES MINIMALFOCUS ON PROCESS EXPERTISE OR
BESTWELD PRACTICES, IT'S TIME FOR SOMEONE
IN THE WELD SHOP TO STEP UP TO THE BLOODY PLATE AND FULLY
COMPREHENDTHE PROCESSES THEY USE.
2013: Note the typical wire feed control(current control) on one
of the world'slargest selling MIG wire feed units.Miller,Hobart,
Lincoln and ESAB havemade wire feed controls for more than
5decades, yet in 2013 not one wire feedcontrol sold provides
information to thewelder on the selection of optimum MIGweld
parameters. By the way I first wrotethis paragraph in the early
nineteeneighties.
You can be sure each day that millions ofwelders around the
globe are playingaround with a wire feed control like this,and they
will end up placing a scratch orpen mark on the feeder.
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IN THE EIGHTIES ED DEVELOPED A UNIQUE MIG / FCAW PROCESS
CONTROLTRAINING METHOD CALLED THE "WELD CLOCK METHOD". THIS METHOD
HASSIMPLIFIED WELD PARAMETER SELECTION AND EVOLVED OVER THE
DECADES
The Weld Clock Method is based on the fact that traditional,
none digital wire feedersdeliver a wire feed rate of 600 to 800
in./min (15 to 20 m/min). The majority of global wire
feeders have provided this wire feed range since the development
of the MIG process.
As with any training method, effective MIG process control
teaching and trainingmethods should always look for the common weld
denominators in the operating orselection of weld parameters.Lets
start out with MIG welding and make the average, global wire feed
rate for a typicalMIG "none digital" wire feeder, approx. 700
in./min.
Ed developed theMIG Clock Method over three decades. The weld
parameter ClockMethod simplifies weld parameter selection for any
carbon steel or stainless applicationand brings together the
relationship between none digital and digital MIG wire feed
settings, the application thickness, weld size and weld
deposition rates.
Most wire feeders will deliver approximately 700 in./min. With
the ten wire feed settings,starting at 7 o'clock and finishing at 5
o'clock. Each turn on the wire feed control wouldtherefore deliver
approx. 70 inch/min per-turn. When you place the wire feed at
themiddle setting, 12 o'clock, this is the fifth turn,5 x 70 = 350
inch/min.
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PANASONIC BS: While Panasonic and other pulsed MIG equipment
manufacturersinform the weld industry that their MIG equipment
offers millions of wave form optionsfor the welds, it's important
that the weld shop understands, that irrespective of theweld
application, steel or alloy welded, with that CV MIG equipment
there are only three"optimum wire feed settings" for each weld wire
and weld transfer mode utilized.
Ed's Weld Clock Method: With an 0.035 (1mm) wire, themajority of
optimum carbon steel and stainless gauge weldswill be made with
short circuit settings found between the 10and 12 o'clock wire feed
positions. Set the wire feed control atthe third setting which is
10 o'clock = 3 x 70 ipm = approx. 210ipm.
At 10 o'clock, this short circuit wire feed setting
deliversapprox. 140 to 150 amp. This current is ideal for all
manual
carbon steel and stainless common gage sizes 0.050 - 0.060 (16
gauge) applications. Setthe weld voltage at 17 volts and when
training the welders, simply tell the welder to
remember a great start point for all carbon steel and stainless
sheet metal MIG welds,is 10 o'clock. with 17 cups of coffee.
MIG or Flux Cored Weld Process Optimization can be this
simple.To set a good Short Circuit weld remember this.
17 CUPS OF COFFEE AT 10 o'clock.
USING TRADITIONAL CV AND PULSED MIG EQUIPMENT? There are 3 easy
toremember, optimum wire feed settings for every MIG weld transfer
mode and and 3
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settings for any flux cored wire irrespective of the
application. Want to learnthesesettings for all MIG wires?
ONCE YOU LEARN ED'S CLOCK METHOD YOU HAVE THE ABILITY TO
ATTAINOPTIMUM WELD QUALITY WITH LOW COST MIG EQUIPMENT. YOU CAN
APPLY THISUNIQUE EASY TO REMEMBER, SIMPLE APPROACH TO ALSO SET
DIGITAL WIRE
FEEDERS AND ROBOT WELD DATA. THIS METHOD IS USED IN ALL ED'S
BOOKS, CDsAND VIDEO WELD TRAINING RESOURCES.
Ed's Weld Clock Method is applicable to all digital feeders and
robot settings.
Watch those robot TIMES and it's influence on RobotArc Starts -
Stops.
At robot weld starts, it's critical for "consistent arcstarts"
to have the weld gas flowing before the arc is
initiated. Poor arc starts occur if there is not sufficientgas,
remember, its the arc plasma "ionized gas" whichis the conductor
for the transfer of electrons across anarc gap.
A robot offers many timed functions that a manualwelder does not
have to deal with. Robot weld time onthe pendent is rarely
calibrated with the actual robottimes. A good thing to know if the
robot timed
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functions are working, is use your ears, if you cannot hear the
changes they aretypically not effective and you may need to
increase the robot times. For example on aweld crater fill, you may
put a second for the crater fill and the time for the crater fill
maybe only a third of a second.
Preflow gas times, ac ignition times, and at the weld ends, arc
delay and crater fill times
etc. With many robots, the different arc timed functions can
accumulate. The arc ignitiontimes may combine with the gas pre-flow
time which may combine with the time inwhich the robot examines the
arc ignition before it allows the weld to commence. Theaccumulation
of weld start function times can result in the robot being
stationary toolong at the weld start.
If a robot sits too long at an arc start when welding thin gauge
parts, it's common to findthe weld size at the weld start is twice
as big as the rest of the weld. The bottom line isthe with thin
gauge welds only use robot times at the arc start if weld start
issues occur.Arc start data becomes much more relevant on parts
> 3 mm.
ROBOTS REQUIRE UNIQUE CONSIDERATIONS FOR WELDING GAUGE
APPLICATIONS.ED'S ROBOT BEST PRACTICES - PROCESS CONTROLTRAINING
CDPROVIDES ALLTHE SOLUTIONS AND THE ROBOT WELD DATA NECESSARY TO
OPTIMIZE ALLCARBON STEELS AND STAINLESS ROBOT WELD QUALITY AND
PRODUCTIVITY.
To see the worlds best weld process for > 16 gage alloy
welds, check outTIP TIG:
MIG WELDING COSTS? In many welding shops there is oftengreater
concern for the cost of the welding wire or gas, than there is
for the cost of the weld.
The objective of a MIG weld decision maker should be
simple.Every time the welder presses the trigger on their MIG or
flux coredgun ensure the weld settings selected should deliver the
desiredweld quality with the wire feed control set as high as
possibleproviding the highest deposition and therefore the lowest
weldcosts.
Placing focus on attainable optimum wire feed and weld
deposition rates for a specificweld application, is achieved
through this weld process controleducation.
Weld Question: Ed. How does the welder know how much weld, they
or arobot will deposit when using the 0.035 (1 mm) wire?
Answer: Its simple. With my unique clock teaching method. For
each turnon a traditional wire feeder, the welder feeding the 0.035
wire at 70 in./min,delivers approximately 1 lb/hr (0.5 kg/hr)
per-turn. So with the 0.035 set atthe 10 o'clock (210 inch/min)
short circuit position, the 10 o'clock setting is
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the third turn and this provides approx. 3 lb/hr. The robot arc
on time per-hr is 20minutes, so the robot deposits a one pound of
wire each hour.
Any MIG or flux cored wire and any weld application. Once Ed's
weld process trainingisprovided,weld quality and production
objectives are fully understood and Weld CostCalculations are Made
Simple.
You can attain your complex weld cost calculation tables from
yourweld equipment or consumable suppliers who are typically ready
to pullanything out of their hats to get your weld equipment and
consumablebusiness. Or deal in Ed's world and use a very
easymethodto controlyour weld costs.
Let's see, all I have to do to control welding costs isprovide
the weld personnel with Ed's self teachingMIG process control
books, or provide thisorganization with process training with the
ProcessControl trainingProgram.These resources willkeep the the
weld shop focus on wire feed anddeposition rates using Ed's easy to
remember WeldCost Clock method. Then I should make sure
myengineers, technicians and supervisors keep their eyes on thewire
feed settings used daily in the shop. Well now, that's worth
looking into.
Weld Question: Ed. How do I know if the traditional none digital
wirefeeder we use delivers the traditional wire feed range of 650
to 750 in./min(16.5 to 19 m/min)?
Answer: Every person who has to use a wire feeder that they have
neverused before would benefit from the following especially if you
go for a joband are required to use a wire feeder you have never
seen before. Also
this simple test will let you know if your wire feeder is
working correctly.
[] Set your wire feed control at the "12 o'clock position"[] Set
the digital wire feeder at 350 inch/min
Press the gun trigger for 10 seconds you should have
approximately 60 inches (1.5 m)of weld wire. Place one end of the
wire under your foot and the other end should cometo the top of the
average size guy's chest.
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2007: NOT ALL WIRE FEEDERS USED IN A WELD SHOP WERE CREATED
EQUAL. Inthe eighties as part of a ridiculous marketing ploy or con
job, some wire feedmanufacturers like Hobart sold high gear ratio,
MIG wire feeders that fed the weld wirefrom 1000 to 1500 inch./min,
(25 to 38 m/min). Other wire feeders were sold that fedmuch lower
wire feed rates
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REGULAR TIG: Play this videofirst: Regular TIG typical manual
weldspeeds for these weldsis typically 4 to 8 inch/min.
The TIG arc on time for this 12 inch weldwould be around 2- 3
minutes.Take a lookat the irregular weld quality influenced bytoo
many arc start / stops, and take specialnote of the large heat
affected zone that'sgoing to create distortion concerns.
Someone can always do a better TIG weld
than this but it will never match the qualityand productivity
attained with TIP TIG.
TIP TIG: Manual TIP TIG weld travel rate48 inch/ min as noted on
the UTube second
counter with this 12 inch length of 3 mm weldmade with an arc on
time of 15 seconds:
Note the uniform weld quality that comes fromthe constant wire
feed rate and only one arcstart / stop. Examine the smooth
clean,unoxidized weld surface, the very small HAZand lack of weld
distortion and weld minimalfumes. Think about the savings that will
resultsfrom less cleaning.
From welding small, long track, 3 mm filletwelds on the deck of
an Aircraft Carrier to the
small size stainless welds typically found onfood and beverage /
processing equipment, noother weld process can provide long, small
sizegage welds with the TIP TIG quality and thelowest possible weld
heat input.
VisitTIP TIGmanual and Automation.
Too many weld shops provide their welders with undersize
oroversized MIG contact tips or gun nozzles, this is simply
anotherindication of lack of weld management.
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Poor tip diameter OD 3 mm. Nozzle ID 9 mm.
How can an industry that has more than50 years of MIG process
expertise, handout to the welders in it's facility contacttips that
are the no thicker than the endof a pen and nozzles so small that
theybecome blocked with spatter in minutes.
Many of the plants that I have been inthat were welding gauge to
6 mm metals,provided their employees with ridiculousthin (< 3
mm) OD contact tips. With
these undesize tips (LEFT) they wouldthen provides nozzles with
ID diameters of approx. 8-9 mm. Withthis situation,the MIG gun
nozzle ID was so small that after five minutes of weld time the
nozzleswould be s blocked with spatter or the contact tip will have
shorted to the nozzleinterfering with the current flow. You can bet
when they are handing out the wrong tipsand nozzles that they don't
have control of the weld spatter.
In one last plant I visited, the welders in the plant did not
seem to mind the ridiculous tipand nozzle consumables they were
given as changing the tips and cleaning the nozzlewas more
comfortable than doing the actual welds. Of course it's logical to
use a smalldiameter nozzles when you cannot get a standard nozzle
size as shown in the rightphoto into the required weld space,
however in many situations the weld joint restriction
is not the issue.
The other amazing thing is once a poor practice like the
innapropriateselection of the gun tips and nozzles are in place,
the weld personnel willoften not want to change to the correct
consumables because "this is theway we have always done it"
The primary value of a weld is based on the wages paidthe
employee and the costs of the weld wires and gasesused, The driving
factor of weld costs is weld deposition
rates provided by wire feed rates and the weld current delivered
throughthat $1 contact tip.In North America you typically have an
annual cost per-welder between$40,000 and and a $60,000. Without
the correct $1 contact tip to transferthe current in a stable
manner and a $8 nozzle that allows the MIG gas to the weld, howmuch
of your weld costs do you believe go flying out of the window every
day?
Understanding the weld tools we work with and the weld
deposition rate potential forour welds, now that will be a first
for our weld shop. Let's face it, we either control thebloody weld
process or let the process and the salesman control us.
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Question. Ed where do we position the contact tip for manual or
robotshort circuit welds?
Answer. To use the lowest voltage for thin gauge parts which
typicallyis required for short circuit welding 16 gauge, place
the contact tip flush with the nozzle.
Question. Ed, we short circuit 0.035 (1 mm) hydroformed gauge
parts. On the seam welds, the lap
joints open up between the robot fixture holdpoints. We always
end up burning through at this
area, any suggestions.
Answer: Use a manual welder or the robot to MIGspot weld the
areas subject to problems. Don't
know how to set a MIG spot weld, it's in my books.
Any manual MIG welder or robot can become a MIG spot welder. You
need no specialequipment, just a little technique and a little
process knowledge that's found in mybooks. You can MIG spot weld
any steel stainless, aluminum or alloy gaugeapplications.
Weld Question: Ed, as most of the wire feeders soldtoday provide
a digital wire feed rate why bother with theclock method?
Answer: The Clock Method "simplifies" optimum weldparameter
selection and it;s extremely easy to rememberany weld setting for
all MIG and flux cored weldapplications.
Digital or none digital when you learn the clock methodyou end
up with the ability to instantly set any manual orautomated weld
without playing with the weld controlsor parameters.
Please remember the traditional, low cost, more durable none
digital wire feeders canlast 10 to 20 years in a welding shop, and
in 2007, there are over a million traditionalwire feeders out
there. As a weld decision maker you will most likely have to work
withthese common durable wire feeders. If you are a professional at
your craft you shouldknow how to set that simple one knob wire feed
control, rather than "play around" withthe controls. If you are a
trainer this method is easy to remember, therefore it's easy
toteach.
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When you combine the optimum weld volts with the optimum
wirefeed, the optimum short circuit welding parameters will produce
acrisp, consistent, rapid crackle sound.
The Sweet Sounds of MIG: Today the majority of MIG welders,use
arc sounds as a method of fine tuning their weld parameters.Arc
sounds are fine but they dont let you know if you areproviding the
required weld deposition rates.
Welders and robot operators should know "the cause of arc
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sounds"and the "correct weld parameter weld control response" to
those arc sounds".
The weld sweet spot or sweet arc sounds attained with short
circuit transfer result whenthe recommended optimum wire feed and
voltage parameters are used. The optimumweld current (wire feed
rate) and weld voltage will result in the maximum amount ofshort
circuits achieved each second. The more rapid the short circuit
crackle sound the
more consistent the "spatter free" weld transfer.
THANKS TO LACK OF WELD PROCESS EXPERTISE,WELD SPATTER COSTS
MILLIONS DAILY:
The welding industry spends millions daily on cleaning
weldingspatter from its parts. The welding equipment manufactures
evenbuild special electronic MIG power sources designed to try
to
produce minimum weld spatter. The weld reality is this. For the
majority of gaugeapplications, when welding with a low cost,
durable, easy to use and easy to repairLincoln, Miller, ESAB, or
Hobart 200-400 amp, CV power source, as this 20 year oldvideo show,
set the correct short circuit or spray welding parameters and you
will attainminimal weld spatter.
Weld Fact: Remember the key to minimizing short circuit weld
spatter is to keep theshort circuit weld drop as small as possible
and create the fastest rate of short circuitweld transfer. This is
achieved working in the recommended SC wire feed range, andensuring
the weld voltage is set to it's minimum.
You don't need to invest in a sophisticated Fronius CMT, Lincoln
STT or a Miller RMDelectronic power source to control weld spatter,
you simply use a traditional low costdurable, low cost CV power
source and teach the welders or robot personnel to set thecorrect
weld parameters. Most weld spatter occurs with short circuit
transfer from atraditional CV power source because the welder has
set their weld volts too high.
Your self taught welders may have 20 years of skills experience,
however pleaseremember "welding skills are not weld process control
expertise" Instead of investing incostly, unnecessary weld
equipment which may be impossible for your electricians torepair,
or buying loads of anti-spatter, surely its more logical to provide
your welderswith some process controltraining.
LETS SEE WE HAVE BEEN BUYING ANTI-SPATTER COMPOUNDS FORTEN
YEARS, AND WE ARE NOW LOOKING AT VERY EXPENSIVEELECTRONIC MIG WELD
EQUIPMENT. WHY WITH A LITTLE WELDPROCESS KNOWLEDGE MY WELDERS COULD
STOP PUTTING THAT COSTLY OIL AND
WATER ON THE PARTS AND WITH THE MONEY I SAVE, ICOULD TRY THAT
MINOXIL AND GET SOME HAIRGROWING BACK ON THIS BUSY HEAD.
This picture proudly presented in a USA weldingmagazine, shows
newly trained, Detroit MIG welderswelding truck frames. The worst
MIG welds found in theindustrial world are found on in auto / truck
frame plants.
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The excessive weld sparks seen in the picture, indicate poorly
tuned manual MIG weldsas evident by the fire works display. The
amount of weld spatter generated is excessiveand it's evident
excessive wire stick outs are being used.
These welders in the photo were trained by a national auto
training organization basedin Detroit, it's purpose to help auto
companies with their weld issues. Obviously the
trainers at this Michigan organization placed little emphasis on
teaching MIG weldprocess control.
It's a sad reality also that whenever you find bad manual MIG
welds, in the same plantyou are sure to find bad robot MIG
welds.
A Self Teaching, Weld Process Controlresourcefor less than
$400may be thesmallest investment we ever make with the largest
return.
How many companies are prepared to invest a few pennies
persupervisor, robot personnel or welders, for weld process
controleducational resources or a training program designed to
optimizeboth the manual or robot welding in their organization?
Shoot, it seems the biggest impediment to the implementation of
effectiveWeld Best Practices and Process Controls in my plant is
the face thatstares back from my mirror.
Most of you reading this weld data will be aware that the
welding personnelat your facility are not aware of all of the weld
data presented at this site. I have a
question for the you, how important is it to your organization
to attain MIG or flux coredmanual or robot weld process controls?
If you think you don't need this type of welddata, do me a favor
and try theMIG welding Spray Transfer quiz,and then ask your
selfhow important is this MIG data to your organization
Consider how easy it is with this unique clock method to bring
your weld personnel intoa lunch room put my CD in your lap top and
project weld data that will optimize the MIGor flux cored welds.
Reduce your product liability and eliminate weld rework. Get
instantcontrol of your weld costs through optimum weld deposition
rates. Get your weld shopinto a professional mode with management
and weld personnel all walking the samepath providing consistent,
daily uniform weld results. Become a weld shop that frownson
individuals that play around with the process parameter
controls.
HOW YOU CAN USE THE CLOCK METHOD FOR OTHER COMMONWIRES. Welding
pipes or structural steels? Do you know theoptimum welding
parameter range settings for an 0.045 (1.2mm)Alloy Rod E71T-1 flux
cored wire, for welding a 1/4 (6mm) filletweld in the vertical up
or over head positions?. What's the singleoptimum setting for that
1/16 (1.6 mm) flux cored wire? With theclock method its simple and
of course flux cored is covered in my books.
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TIP TIG 409 16 GAGE SEAM WELDS.TIP TIG 409 16 GAGE SEAM
WELDS
IF VIDEO PAUSES PLAY A SECOND TIMEIf you compared short circuit
or pulsed MIG with this TIPTIG seam weld or any other steel or
alloy seam gaugewelds, you would instantly note the superior weld
qualityfrom TIP TIG. While the MIG welds may have fumeconcerns,
oxide formation, spatter, distortion and possiblyrequire manual
cleaning or weld rework, in contrast theTIP TIG welds would not
create these common weldproduction issues.
Customer wanted to see thequality and productioncapability for
TIP TIG on this
seam application. Theautomated set up was easy,
just attach the TIP TIG torch tothe auto carriage.
Nosophisticated equipmentrequired like complex plasmaor Arc Volt
Controls. Within 10minutes the TIP TIG wasproducing the parts shown
onthe left. With automated TIP TIGseam gage welds such as this,you
can anticipate the weldswould be made between 25 - 35
inch/min. (500 to 700% quickerthan manual TIG)